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ROADHEADER IN TUNNELING TODAY’S STATE-OF-THE-ART-ROADHEADER
ROADHEADER IN TUNNELING TODAY’S STATE-OF-THE-ART-ROADHEADER
Sandvik’s objective is zero harm to our people, the environment we work in, our customers and our suppliers.
SAFETY FIRST
PROTECTIVE EQUIPMENT
ASSEMBLY POINT
EMERGENCY EXIT
EMERGENCY NUMBER
ALARM FIRST AID KIT
3
COMPLIANCE COMPLIANCE We’ve always been committed to conducting business with high integrity and in a legal and ethical manner. We embrace our corporate responsibility to combat corruption.
MECHANICAL TUNNEL EXCAVATION
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Mechanical Tunnel
Excavation
Part face excavation
Soft (lose) rock
Full face excavation
Hard (stable)
rock
TUNNELING SHORT COURSE 2016 CONTENT
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• Selection criteria for Excavation method
• Parameter on Roadheader Cuttability
• Current Roadheader technology
• Roadheader projects
SELECTION CRITERIA FOR EXCAVATION METHOD
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ROCK PROJECT ENVIRONMENT
Drill & Blast
Shield Machines
Hard rock TBM’s
Excavator Attachments
Roadheaders
Compressive Strength
Stab
ility
/ Fr
actu
ring
Mechanical Excavation with Breaker / Splitter
SELECTION CRITERIA FOR EXCAVATION METHOD EXAMPLES – ROADHEADER SELECTION
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• Complex geology • Free access to the face • Ability for partial face excavation • Gentle excavation • Not sensitive against squeezing rock • High cutting performance in soft and
medium hard rock (up to 130 m³/NCH)
SELECTION CRITERIA FOR EXCAVATION METHOD EXAMPLES – ROADHEADER SELECTION
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• Flexible system – profile, alignment • Accurate profiling – less over break,
less concrete cost • Low primary investment • Fast mobilization
PARAMETER FOR ROADHEADER CUTTABILITY REPRESENTATIVE ROCK SAMPLING
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Batching Card for Sample Identification
PARAMETER FOR ROADHEADER CUTTABILITY UNCONFINED COMPRESSIVE STRENGTH TESTING
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• Determination of: σc, Estat, Esec, ε, Wf
• Standard specimen: −D = 50 mm ± 10 % −H = D ± 10 %
• Load: − F = 10 kN/s
H
D
F
PARAMETER FOR ROADHEADER CUTTABILITY BRAZILIAN TENSILE STRENGTH TESTING
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• Determination of: σt
• Standard specimen: −D = 50 mm ± 10 % −H = D/2 ± 10 %
• Load: − F = 10 kN/s
F
H D
PARAMETER FOR ROADHEADER CUTTABILITY CERCHAR ABRASIVITY INDEX (CAI) TESTING
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• Standard Test Pick Hardness: HRC = 54 - 56 • Optional Test Pick Hardness: HRC = 40 - 42 • Steel Type: Silver Steel 115CrV3 (DIN) • According to
− 1.2210 Material Number(DIN EN ISO 4597) − 107CrV3 KU in Italy (UNI) − F.5125 (120CrV) in Spain (UNE) − 11ChF in Russia (GOST) − L 2 in USA (AISI)
CAI Testing
CAI Measuring
PARAMETER FOR ROADHEADER CUTTABILITY CERCHAR ABRASIVITY INDEX (CAI) TESTING
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• 10 mm in 1 second over rough surface
• Load: F = 70 N
• CAI = 10 x d [mm]
. 90° d
10 mm
F F
new pick before testing
worn pick after testing
d
Pick wear diameter
PARAMETER FOR ROADHEADER CUTTABILITY HOW TO ASSESS NCR FOR INTACT ROCK
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• UCS = 100 MPa • UCS:BTS = 8 to15
− Normal rock
Technical limit defined by machine Economical limit defined by operation
PARAMETER FOR ROADHEADER CUTTABILITY OPERATING LIMITS DEFINED BY NCR
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Technical optimum range of operation Limited range
Critical range
PARAMETER FOR ROADHEADER CUTTABILITY HOW TO ASSESS SPC
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0,001
0,010
0,100
1,000
10,000
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180
Spec
ific P
ick C
onsu
mptio
n [pi
cks/s
olid
m³]
Uniaxial Compressive Strength [MPa]
Specific Pick Consumption (SPC) for Low Speed Cuttingwith Transverse Cutterhead and 22 mm TC Diameter Picks of High Quality
CAI=0,5CAI=1,0CAI=1,3CAI=1,8CAI=2,3CAI=3,0CAI=4,5
Effective minimum specific pick consumption: 0,005
Uniaxial Compressive Strength measured onH:D=1:1 specimen with 50 mm diameter @ 10
CAI ..... CERCHAR Abrasivity Index measuredon rock surface of natural roughness (e.g.surface of broken Brazilian Tensile Strength testspecimen) using original CERCHAR testing
UCS=100 MPa CAI=1.0
Technical limit defined by machine & tools Economical limit defined by operation
PARAMETER FOR ROADHEADER CUTTABILITY OPERATING LIMITS DEFINED BY SPC
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Technical optimum range of operation Limited range Critical range
PARAMETER FOR ROADHEADER CUTTABILITY INFLUENCE ON ROCK MASS PARAMETERS
Sandvik Construction 18
PARAMETER FOR ROADHEADER CUTTABILITY PRINCIPLES OF ROCK MASS INFLUENCE
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Strength
Conditions Orientation
0.5 m
0.3
m
0.3 m Block size
PARAMETER FOR ROADHEADER CUTTABILITY ROCK MASS CUTTABILITY RATING (RMCR) SYSTEM
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Block size [m3] Rating> 0,6 20
0,3 - 0,6 160,1 - 0,3 10
0,06 - 0,1 80,03 - 0,06 50,01 - 0,03 3
< 0,01 1
Surface Aperture Wall/Fill Rating Influence on cuttability
Rating
rough closed hard, dry 30 very favorable -12slightly rough
< 1 mm hard, dry 20 favorable -10
slightly rough
< 1 mm soft, dry 10 fair (and if block size <0,03m3)
-5
smooth 1 - 5 mm soft, damp 5 unfavorable -3very smooth
> 5 mm soft, damp to wet
0 very unfavorable 0
Rating of joint conditions Rating of orientation of joint set
100 - 200 2> 200 1
25 - 50 750 - 100 4
1 - 5 155 - 25 12
Rating of block size
UCS [MPa] Rating
Rating of uniaxial compressive strength
Evaluation of Rock Mass Influence on NCR(Low cutting speed - 1.4 m/s)
NCReff/NCRtheor = 45,553RMCR-0,9821
R2 = 0,9332
0123456789
10
0 10 20 30 40 50 60
RMCR
NCR e
ff / N
CRth
eor
Erzberg Stillwater PozzanoPremadio Athens BilecaFresnillo Montreal
PARAMETER FOR ROADHEADER CUTTABILITY HOW TO ASSESS NCR FOR ROCK MASS
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RMCR = 30 => increase in NCR ~ 60%
PARAMETER FOR ROADHEADER CUTTABILITY HOW ROCK MASS IMPACT ROADHEADER CUTTABILITY
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Rock mass favorable for cutting can make an uneconomical or critical operation economical!!!
RMCR = 30
Technical optimum range of operation Limited range
Critical range
PARAMETER FOR ROADHEADER CUTTABILITY ROCK MASS CUTABILITY RATING (RMCR) SYSTEM
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RMRrev Influence on cuttability by roadheaders
40 - 60 no to little influence25 - 40 moderate influence15 - 25 considerable influence10 - 15 high influence
< 10 dominating influence
RMCR
CURRENT ROADHEADER TECHNOLOGY MT720 ROADHEADER WITH ICUTROC TECHNOLOGY
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• MT720 Tunnel Miner − Heavy-duty Roadheader for tunneling in
“hard rock conditions“ − Especially designed for large cross sections
• Key Technical data
− Weight: ~135 t − Cutter motor power: 300 kW − Large cutting area: ~61 m² − Fully PLC controlled − ICUTROC technology
CURRENT ROADHEADER TECHNOLOGY MT720 ROADHEADER WITH ICUTROC TECHNOLOGY
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• Highly efficient stabilized CUTTING SYSTEM
CURRENT ROADHEADER TECHNOLOGY MT720 ROADHEADER
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• Different cabin designs (FOPS) • Roadheader without cabin • Profile monitoring (optional) • Guidance system (optional)
CURRENT ROADHEADER TECHNOLOGY MT720 ROADHEADER WITH ICUTROC TECHNOLOGY
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• Keeping records with DATALOGGING SYSTEM
• DRRS – Data Recording & Reporting System
IPC
Control system
Ethernet
EthernetUnderground
Surface
Sandvik supply
Customer supply
ATM 105
Provisions for:
1. Remote Maintenance (not included)2. Data storage (not included)3. Online monitoring (not included)
Benefits
110 – 240 VAC
ROADHEADER PROJECTS ROADHEADERS WORKING IN CONSTRUCTION PROJECTS
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• Project in Sochi for 2014 Olympics
• 2010 until 2012/13
• 2 x ATM75 and 2 x MR360 and 1 x MT360
• 4 x MT520
• 3 x ATM105 and 1 x AHM105 and 2 x MT720
• Projects in Europe • 2015/16 1 x MT720 @ Pforzheim, Germany
• 2013/14 1 x MT720 @ Bormio, Italy
• 2012/13 1 x MT520 @ Polidano, Malta
• 2011/12 1 x MT720 @ Markovec Tunnel
• 1999/2010 7 x MT720 @ Bilbao, Spain
• Projects in North America • 2017/18 2 x MT520 @ Peace River Hydro
• 2013/16 3 x MT720 @ Ottawa Light Rail
• 2008/10 3 x MT720 @ East Side Access
• 2007/08 2 x MT720 @ Devil’s Slide
• 2007/08 1 x MT720 @ Arch
• 2004/05 1 x MT720 @ Fox River stone
• 2002/03 2 x MT720 @ Metro Montreal
• Project in Australia • 2009/10 8 x MT720 @ Airport Link Brisbane, Australia
• 2016/18 24 x MT720 & MT520 @ NorthConnex and WestConnex Sydney, Australia
ROADHEADER IN TUNNELING MARKOVEC TUNNEL, SLOVENIA
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• Project data − 2,2 km double twin tube road tunnel between Koper
and Izola (Slovenian Coastline) − Residential area at Koper side with overburden of
10-35m − 560m in each tube to be excavated by means of
Road-Header • Geologic data
− Flysch dominated by Marl − Interbeds of Sandstone and Calcarenite (UCS up to
200 MPa) − Area with shallow overburden weak rock predicted − Sandstone layer thickness of 2m
Source: Alpine Bau GmbH, Austria UNDER CITY Colloquium April, 12- 14, 2012 Hotel-Congress center Valamar Lacroma Dubrovnik, Croatia Excavation by means of Road Header at Markovec Road Tunnel
ROADHEADER IN TUNNELING MARKOVEC TUNNEL, SLOVENIA
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• Up to 8 m/d
ROADHEADER IN TUNNELING ST. LUCIA TUNNEL BORMIO, ITALY
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• Project data − About 1km single tube road tunnel − Bypass of Bormio residential area
• Geological data
−Quartzitic mica schist −Gneiss −UCS values between 40 – 200MPa −CAI 2,5 – 5
ROADHEADER IN TUNNELING ST. LUCIA TUNNEL BORMIO, ITALY
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ROADHEADER IN TUNNELING ST. LUCIA TUNNEL BORMIO, ITALY
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• ~ 4m/day
0.0
10.0
20.0
30.0
40.0
50.0
60.0
70.0
80.0
90.0
0
5
10
15
20
25
30
MPA
SOLI
D M
³/CU
TTER
MO
TOR
HO
IOU
RS
Net cutting rate UCS
ROADHEADER IN TUNNELING METRO MONTREAL, CANADA
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• Project data − Metro tunnel − Length: ~1.8 km − Cross section: ~44 m²
• Geologic data
− Limestone-shale interbedding, massive crystalline limestone, diabase dikes
− Average UCS: ~90 MPa − Average CAI: ~0.7 − Very well bedded rock mass − Average NCR: ~39 solid m³/nch − Average SPC: ~0.1 picks/solid m³
ROADHEADER IN TUNNELING METRO MONTREAL, CANADA
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Better advance rate than D&B related to single face operation
ROADHEADER IN TUNNELING METRO MONTREAL, CANADA
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• Visible arguments for Roadheader
ROADHEADER IN TUNNELING STATION EXCAVATION, EAST SIDE ACCESS
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• Project data • Metro station excavation
• Launch chamber for TBM
• Additional auxiliary structures
• Small to large cross sections
• Geologic data • Schist (partly gneissic), pegmatite
• Average UCS: ~80-95 MPa
• Average CAI: ~3.7-3.8
• Massive to significantly fractured
rock mass
ATM105/046 at New York/USA
0
5
10
15
20
25
30
16.1
1.20
09
04.0
2.20
10
25.0
4.20
10
14.0
7.20
10
Date
Net C
uttin
g Ra
te [s
olid
m3 /h
]
0,0
0,5
1,0
1,5
2,0
2,5
3,0
3,5
4,0
4,5
5,0
5,5
6,0
Spec
ific
Pick
Con
sum
ptio
n [p
icks
/sol
id m
3 ]
Daily NCR Cumulative Average NCR Daily SPC Cumulative Average SPC
Average NCR: 17,71 solid m3/h
picks/solid m31,526Average SPC:Net Cutting Rate (NCR) and Specific Pick Consumption (SPC)
ROADHEADER IN TUNNELING STATION EXCAVATION, EAST SIDE ACCESS
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ROADHEADER IN TUNNELING NORTHCONNEX AND WESTCONNEX, AUSTRALIA
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• Connecting M1 at Wahroonga to M2 at West
Pennant
• Extension work on M4
Total 21 Sandvik Roadheaders (MT720, MT520)
ROADHEADER MT720 ICUTROC LATEST PROJECT EXPERIENCES - CONCLUSIONS
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• The ICUTROC technology has proven
• ... to be an economic alternative for challenging excavation projects • ... the ability to deal with harder & sensitive rock condition forming low risk for the
Contractor/Owner • ... high productivity resulting in low excavation cost
SANDVIK IN TUNNELING
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UNDERSTANDING UNDERGROUND
